Product Development Engineer - Powertrain Cast Structures

Ford Motor Company; Livonia (MI); Hybrid; USD 65,000 - 170,000; Full time

Benefits offered by this job

Medical coverage

Dental/Vision coverage

Vehicle discount

Tuition assistance

Paid time off

Paid holidays

Job summary

Ford Motor Company in Michigan is seeking a Powertrain Structures PD Engineer to own design, development, and release of cast structures components for EV/Hybrid/ICE powertrains. You will manage CAD/BOM structures, support CAE and physical testing, and drive design improvements with global manufacturing teams.

The role emphasizes quality, cost, weight, and functional performance across concept to production, with collaboration across engineering, supplier, and plant teams.

Qualifications

• Bachelor's degree in Engineering (Mechanical preferred).
• 2+ years in high‑pressure die casting and casting design.
• 1 year of CAD experience.

Responsibilities

• Develop cast structures components with powertrain teams.
• Lead design validation and FMA activities.
• Manage prototype/production build delivery and quality.
• Develop structural design to meet powertrain/vehicle attributes.
• Lead supplier selection to achieve program targets.
• Release 3D/2D CAD meeting design requirements.
• Support CAE testing of structure design prior to tooling.

Skills

CAD (Catia)

CAE analysis

GD&T

FMA/DFMEA

Project leadership

Education

Bachelor's degree in Engineering (Mechanical preferred)

Master's degree (preferred)

Tools

Magma

CATIA

Job description

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position...

Exciting opportunity to develop the future of Ford Motor Company in the group that designs and releases cast structures components and housings for EV, Hybrid, and ICE Power Units. The automotive industry is quickly working to develop new powertrains to meet evolving customer and market demands, creating an expanding need for new and modified powertrain structures components. Powertrain cast structures components perform many critical functions and are among the most strategic components in a BEV/Hybrid and ICE powertrain. As the engineer for powertrain structures components, you will have the unique opportunity to own all stages of product design, development, and release — from concept to full-scale production — with an emphasis on quality, cost, weight, and functional performance.

The PD Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.

The PD Engineer is expected to understand and effectively utilize product check-in/check-out processes, version control, data release, and change management within Ford’s PLM ecosystem.

The PD Engineer will perform feasibility analyses using CAD tools, including draft angle analysis, undercut detection, minimum bend radius validation for sheet metal, and clearance checks to support manufacturing and machining requirements.

What you'll do...

• Develop cast structures components in conjunction with powertrain systems and internal/external global manufacturing teams.
• Lead component design, validation, and FMA (Failure Mode Analysis).
• Manage prototype and production build delivery and quality.
• Develop structural design to meet powertrain and vehicle attributes including strength, durability, and NVH.
• Lead Purchasing, Finance, and Cost Estimating in supplier selection to achieve program targets
• Interface with engineers of surrounding components and systems (gears, bearings, pumps, mounts, e-motor, etc.).
• Interface with engineers within internal and external manufacturing teams (casting, machining, assembly).
• Release 3-D and 2-D CAD that meets system and component design requirements.
• Support Ford CAE testing of structure design prior to tooling (strength, NVH, casting analysis).
• Support Ford physical testing of structure design.
• Complete FMA and related quality documentation.
• Kick off and track supplier and Ford manufacturing and tooling.
• Lead Ford internal and external supplier CPMT (Component Product Management Team) for assigned components.
• Deliver Final Engineering Sign-off and support production vehicle launch at Ford assembly plants.

You'll have...

Bachelor's degree in Engineering, mechanical engineering preferred or similar.

2+ years of industry experience with high pressure die cast components and strong knowledge of casting design and best practices.

1 year of CAD experience.

Even better, you may have...

Master's degree in Engineering, mechanical engineering preferred or similar.

Industry experience with aluminum machining, with strong knowledge of machining best practices and GD&T.

Working knowledge of casting simulation tools (Magma).

Working knowledge of CAD and CAE (Catia).

Experience applying 8D, fishbone, and DOE problem-solving methodologies.

Experience creating Boundary Diagrams, P‑Diagrams, and DFMEA.

Experience reviewing CAE models and CAD drawings.

Experience maintaining DVP&R and signing off on DV tests.

Self-starter Who Can Identify Improvements And Motivate Others.

Strong communication skills with the ability to present information concisely.

Ability to think like a businessperson while remaining technically astute.

Ability to manage multiple projects simultaneously.

Strong leadership, project management, and team-building skills, with a demonstrated ability to work cross-departmentally.

Strong collaborator, willing to share ideas, documentation, and best practices.

Excellent oral and written communication skills.

Proficiency in Microsoft Office (Word, Excel, PowerPoint).

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply!

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year's Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 5 and ranges from $65,100-$109,300.

This position is a salary grade 6 and ranges from $74,300-$124,500.

This position is a salary grade 7 and ranges from $86,600-$144,900.

This position is a salary grade 8 and ranges from $99,100-$166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid with a requirement to be onsite four or more days per week.